Ultralite™: The ‘Hidden’ Energy Saver
In an era where energy costs and carbon footprints are under intense scrutiny, Mantec Technical Ceramics is helping the sector rethink one of its most overlooked areas of heat loss: the kiln car.
Transforming Kiln Efficiency
Based in the heart of Staffordshire, Mantec is a multifaceted manufacturing technology powerhouse with a heritage spanning over 50 years. Far more than a traditional supplier, Mantec has evolved into a vital innovation partner for global industries, serving diverse sectors ranging from Heavy Clay and Sanitaryware to Aerospace, Defence, and Water Treatment.
Tackling the ‘Silent’ Drain on Profitability
While much of the industry’s focus remains on burner efficiency and wall insulation, the massive thermal mass of kiln cars, which cycle through high temperatures thousands of times, can be a significant, silent drain on a plant’s profitability.
Mantec’s Ultralite™ range is engineered to tackle this inefficiency head-on. Utilising advanced microporous refractory technology, Ultralite™ offers a high-performance alternative to traditional dense materials that historically soak up and store unnecessary heat.
What Makes Ultralite™ Different?
The secret to Ultralite™ lies in its engineered structure. It features high open porosity and low permeability, resulting in a material that is incredibly lightweight with exceptionally low thermal mass.
By drastically reducing the energy required to heat the kiln furniture itself, manufacturers can achieve a direct and immediate reduction in fuel consumption. In fact, switching to Ultralite™ can save up to 40% on kiln car energy costs.
Precision Engineering: Two Specialised Solutions
To meet the rigorous and varied engineering demands of modern ceramics production, Mantec provides this technology in two versatile formats:
Ultralite™ Loose Fill (ULF):
A superior alternative to traditional cavity insulators like expanded clay or vermiculite. It is particularly effective as a safer, more sustainable replacement for Refractory Ceramic Fibre (RCF) in kiln car bases.
Ultralite™ Refractory Castable (URC):
Designed for applications requiring structural integrity, URC blends Ultralite™ technology with high-grade refractory aggregates and cements. This allows for the precision casting of complex solid shapes.
Both solutions are available in three different temperature grades to suit specific firing requirements.
Driving the Sector Toward Net Zero
As the UK ceramics sector moves toward the Net Zero transition, every percentage point of efficiency becomes a competitive advantage. Ultralite™ isn’t just a cost-saving measure; it is a strategic tool for improving cycle times and reducing the overall carbon intensity of the firing process.
By focusing on these ‘hidden’ energy savers, Mantec is proving that for the modern manufacturer, the most significant gains often come from the smallest pores.
“Ceramics shape the world around us – from the homes we live in to the cup we hold each morning. But their impact goes far beyond the everyday: they enable the production of steel for bridges, critical components for aircraft engines, and the technology that powers our smartphones.
In short, ceramics make modern life possible-and the UK stands as a global leader in this vital field. At Mantec Technical Ceramics, we are proud to provide products that support all these sectors and more.”
